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I agree with Peetz that a suitable welded repair can be done from the outside surface of the door.
However, if you do decide you want reinforcement on the inside, that can be done even though the welding is on the outside (with the door in place). When I went through aircraft mechanic's training we learned to do the reverse of what I'm going to suggest, but only because the method was used in areas where there was no access to place a reinforcement on the inside/backside of the structure.
I'm not sure how much room you have, but the idea is to drill some holes through the affected area adjacent to the crack. With the reinforcement in place, you do "rosette" welds around the edges of those holes and into the reinforcement. This joins the door metal to the reinforcement.
If I was doing the repair, I'd also open the crack slightly by grinding and do a bead along it's length, joining the door metal to the reinforcement.
The wet towel(s) idea will protect the finish near the welded area.
Tatra Mike
Seattle, Washington
1985 244 "Alfsen" (wife's car - the good one)
1984 245 "Buster" (the kid's car, now sold)
1985 245 "Cosmo" (parts car, sold off for move to WA)
1985 245 "Daisy" (back seat down, full of tools, the work truck)
1985 245 "Earl (CA vehicle 'retirement' program)
Can you tell I prefer the 1985 model 240? Better headlights than
the plastic 1986+ and nicer belt adjustments than the 1984s and earlier!
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